Modular Oscillatory Flow Plate Reactor with 2D Constrictions
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Conventional oscillatory flow reactors face challenges with solid handling, particularly solid deposition and fouling, especially under low oscillatory conditions, and are limited in their application to systems like crystallization due to secondary nucleation and agglomeration issues.
Innovation Solution
The development of a plate reactor with 2D smooth periodic constrictions, featuring specific geometric parameters such as tube width, constriction length, and curvature, which allows for improved mixing intensification and reduced fouling, enabling operation in both batch and continuous modes, and facilitating easy cleaning and modular design.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional oscillatory flow reactors use low oscillatory conditions to improve mixing, then energy consumption is reduced, but solid deposition and fouling increase
Solution Approach 1:
The patent changes the geometric parameters of the reactor, specifically introducing 2D smooth periodic constrictions with optimized dimensions (constriction length L1=0.5-3×Dw, straight section length L2=1-5×Dw, curvature radius Rc=0.1-0.5×Dw) to modify flow patterns. This allows achieving effective mixing at lower oscillation amplitudes while preventing solid deposition and fouling through improved flow distribution and reduced stagnant zones.
2Productivity
If conventional oscillatory flow reactors use smooth periodic constrictions to reduce fouling, then mixing efficiency improves, but secondary nucleation and agglomeration occur in crystallization systems
Solution Approach 1:
The patent applies different geometric characteristics to different sections of the reactor. The convergent section has specific curvature radius (Rc=0.1-0.5×Dw) and length (L1=0.5-3×Dw) to control flow acceleration and mixing, while the straight section (L2=1-5×Dw) provides stable flow for product formation. This local optimization allows efficient mixing without creating excessive shear stresses that cause secondary nucleation and agglomeration in crystallization systems.
3Ease of manufacture
If conventional oscillatory flow reactors use fixed geometry to simplify design, then manufacturing is easier, but adaptability to different systems and scales is limited
Solution Approach 1:
The patent designs a universal reactor geometry with dimensionless parameters that can be scaled and adapted to different applications. The constriction dimensions (L1, L2, Dw, Rc) are expressed as multiples of the tube diameter, allowing the same basic design to be applied to various systems including bioprocess, gas-liquid absorption, liquid-liquid extraction, precipitation, and crystallization, both at meso and macro scales.
Solution Approach 2:
The patent incorporates adjustable oscillation parameters (frequency and amplitude) that can be dynamically modified to suit different process requirements. The reactor geometry is designed to work effectively across a range of oscillation conditions, allowing adaptation to different systems and operating modes (batch or continuous) without changing the fundamental design.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The 2D smooth periodic constrictions enhance mixing efficiency, reduce fouling and secondary nucleation, and expand the reactor's applicability to multiphase systems, including crystallization, by optimizing geometric parameters and allowing for flexible operation across various industrial processes.
Implementation Method 1
The liquid or multiphase fluid is typically oscillated in the axial direction by means of diaphragms, bellows or pistons, at one or both ends of the tube, developing an efficient mixing mechanism where fluid moves from the walls to the centre of the tube with intensity controlled by the oscillation frequency (f) and amplitude (x 0 ).
Implementation Method 2
The formation and dissipation of eddies, in these reactors, has proved to result into significant enhancement in processes such as heat transfer, mass transfer, particle mixing and separation
Data Source
Figure 1
Figure 2
Figure 3
AI summary
The present application relates to an improved apparatus for mixing intensification in multiphase systems, which can be operating in continuous or batch mode. In particular, it relates to a reactor, which can be assembled and disassembled easily for cleaning. The apparatus is based on oscillatory flow mixing (OFM) and comprises an oscillatory flow plate reactor (OFPR) provided with 2D Smooth Periodic Constrictions (2D-SPCs). The apparatus can be fully thermostatized and it is based on a modular system, in order to achieve most of the industrial application. The OFPR is suitable for multiphase applications such as screening reactions, bioprocess, gas-liquid absorption, liquid-liquid extraction, precipitation and crystallization. Regarding its size and geometry and the ability to operate at low flow rates, reagent requirements and waste are significantly reduced, as well as the manufacturing and operating costs, compared to the common reactor, such as continuous stirred tank reactor (CSTR) and the "conventional" OFR.